US20190101145A1 - Joint structure - Google Patents

Joint structure Download PDF

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Publication number
US20190101145A1
US20190101145A1 US16/087,145 US201716087145A US2019101145A1 US 20190101145 A1 US20190101145 A1 US 20190101145A1 US 201716087145 A US201716087145 A US 201716087145A US 2019101145 A1 US2019101145 A1 US 2019101145A1
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United States
Prior art keywords
metallic material
projection
different type
welding
metallic
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US16/087,145
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English (en)
Inventor
Junji Fujiwara
Atsuhiro Kawamoto
Hitoshi Nishimura
Yasushi Mukai
Shigeki Yonemori
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Panasonic Intellectual Property Management Co Ltd
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Panasonic Intellectual Property Management Co Ltd
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Assigned to PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD. reassignment PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NISHIMURA, HITOSHI, MUKAI, YASUSHI, FUJIWARA, JUNJI, KAWAMOTO, ATSUHIRO, YONEMORI, SHIGEKI
Publication of US20190101145A1 publication Critical patent/US20190101145A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
    • B23K9/232—Arc welding or cutting taking account of the properties of the materials to be welded of different metals
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/08—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of welds or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
    • B23K11/18—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded of non-ferrous metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
    • B23K11/20—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded of different metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/007—Spot arc welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/02—Seam welding; Backing means; Inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/235—Preliminary treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/006—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/18—Sheet panels
    • B23K2101/185—Tailored blanks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • B23K2103/05—Stainless steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/10—Aluminium or alloys thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/18—Dissimilar materials

Definitions

  • the present disclosure relates to a joint structure including similar types of metallic materials and at least one different type of material sandwiched between the metallic materials.
  • the joint structure is produced using arc or plasma as a heat source.
  • spot welding is popular in this industry.
  • this welding is a kind of resistance welding, in which materials to be welded are pressurized by upper and lower electrodes used as a spot welding gun until there is no gap left between the materials, and then the electrodes are energized.
  • spot welding is not suitable for one side welding.
  • Spot welding also imposes limitations on the product shape because the part to be welded has to be sandwiched from above and below by the gun.
  • Another disadvantage of the welding is that pressurizing the part to be welded needs a space into which the gun enters above and below the materials to be welded.
  • spot welding takes additional time, such as the time to carry the heavy gun, the time to pressurize the materials after the gun reaches the part to be welded, and the time to cool the welded part.
  • Patent Literature 1 discloses the following techniques: a pressurization method in which a rivet and a material of the same type as the rivet sandwich a different type of material and pressurize it; a rivet having a shape capable of absorbing the plastic flow of the different type of material caused by welding heat input; and methods of crimping and spot welding capable of the absorption.
  • This configuration ensures the space into which deformed part of the different type of material is moved during the crimping and spot welding.
  • the configuration also prevents depression of the different type of material due, for example, to misalignment of the electrodes during spot welding, thereby maintaining the joint strength.
  • the joint structure according to the present disclosure includes a first metallic material having a first projection, a second metallic material similar in type to the first metallic material and weldable to the first metallic material, and a different type of material different in type from the first metallic material and the second metallic material, the different type of material having a first penetrating part and sandwiched between the first metallic material and the second metallic material, the different type of material being difficult to be welded to the first metallic material and the second metallic material.
  • the first projection is smaller in diameter or width than the first penetrating part and is spaced radially or widthwise from the rim of the first penetrating part by a first gap.
  • the first projection is positioned in the first penetrating part and is spaced from the second metallic material by a second gap in the thickness direction of the first penetrating part.
  • the second gap has the size of a predetermined percentage of the thickness of the first projection of the first metallic material to which arc welding id applied.
  • FIG. 1 is a schematic diagram of a joint structure during arc welding according to a first exemplary embodiment of the present disclosure.
  • FIG. 2 is a schematic diagram of a joint structure during arc welding according to a second exemplary embodiment of the present disclosure.
  • FIG. 3 is a schematic diagram of another joint structure during arc welding according to the second exemplary embodiment of the present disclosure.
  • FIG. 4 is a schematic diagram of another joint structure during arc welding according to the first exemplary embodiment of the present disclosure.
  • FIG. 5 is a schematic diagram of another joint structure during arc welding according to the first exemplary embodiment of the present disclosure.
  • FIG. 6 is a graph showing the measurement results of the relationship between the thickness of the first material and the size of the second gap in the thickness direction according to the first exemplary embodiment of the present disclosure.
  • FIG. 7 is a graph showing the measurement results of the relationship between the type of the second material and the size of the first gap according to the first exemplary embodiment of the present disclosure.
  • FIG. 8 is a schematic diagram of another joint structure during arc welding according to the first exemplary embodiment of the present disclosure.
  • FIG. 9 is a schematic diagram of another joint structure during arc welding according to the first exemplary embodiment of the present disclosure.
  • FIG. 10 is a schematic diagram of a joint structure during arc welding according to a third exemplary embodiment of the present disclosure.
  • FIG. 11 is a schematic diagram of another joint structure during arc welding according to the third exemplary embodiment of the present disclosure.
  • FIG. 12 is a schematic diagram of another joint structure during arc welding according to the third exemplary embodiment of the present disclosure.
  • FIG. 13 is a schematic diagram of a joint structure during arc welding according to a fourth exemplary embodiment of the present disclosure.
  • FIG. 14 is a schematic diagram of joining different types of materials together in a conventional manner.
  • Crimping and spot welding uses a space to accommodate the deformed part of a different type of material 200 .
  • electrode 400 is to be prevented from being misaligned during spot welding so as to prevent depression of material 200 , thereby maintaining the joint strength between the joint members.
  • Rivet 51 with such a complicated shape can be fabricated by high precision processing technology, thus increasing the production cost.
  • spot welding which is a kind of resistance welding, involves time-consuming processes, such as pressurization, energization, cooling, and transfer.
  • a set of joint members 100 is sandwiched from both sides, which indicates a low degree of design freedom.
  • a desired nugget without current diversion can be formed by setting the pitch between adjacent rivets at not less than the minimum pitch. Therefore, rivets cannot be arranged at a pitch not more than the minimum pitch, making it impossible to improve joint stiffness at required positions.
  • the present disclosure provides a simple joint structure that can join different types of materials together by arc or plasma welding so as to improve the throughput.
  • FIG. 1 shows a joint structure composed of the following joint members: first material 1 , which is the first metallic material of the present disclosure; third material 3 , which is the second metallic material of the present disclosure, and which is similar in type to first material 1 ; and second material 2 , which is different in type from first and third materials 1 and 3 .
  • FIG. 4 is a schematic diagram in which the upper plate is circular-shaped first material 1 .
  • FIG. 5 is a schematic diagram in which the upper plate is rectangular-shaped first material 1 .
  • the lines I-I shown in FIGS. 4 and 5 correspond to the cross sectional view of FIG. 1 .
  • first material 1 and third material 3 both made of metal are joined together with second material 2 as a different type of material
  • second material 2 is sandwiched between first and third materials 1 and 3 .
  • First material 1 and third material 3 are similar types of metallic materials and weldable to each other.
  • Second material 2 is different in type from and is difficult to be welded to first and third materials 1 and 3 .
  • Second material 2 has first through-hole 11 , which is an example of the first penetrating part of the present disclosure.
  • First material 1 has first projection 4
  • third material 3 has second projection 5 .
  • Projections 4 and 5 are positioned in first through-hole 11 in such a manner as to oppose each other. This arrangement prevents misalignment of first and third materials 1 and 3 with respect to first through-hole 11 . It therefore becomes possible to visually check the mark of an arc welding position and the appropriateness of the position of the bead.
  • the first penetrating part is first through-hole 11 in the present exemplary embodiment, but may alternatively be, for example, a through groove.
  • materials 1 and 3 can be a combination of ferrous metals, such as two types of mild steel; mild steel and stainless steel; two types of stainless steel; mild steel and high-tensile steel; high-tensile steel and stainless steel; and two types of high-tensile steel.
  • Materials 1 and 3 can also be a combination of nonferrous metals, such as two types of aluminum; aluminum and an aluminum alloy; and two types of aluminum alloys.
  • Second material 2 is defined as a material different from and difficult to be welded to first material 1 and third material 3 , which are of similar types.
  • first material 1 and third material 3 are ferrous metals
  • second material 2 is nonferrous metal, such as copper or aluminum.
  • second material 2 is resin, such as carbon fiber reinforced plastic (CFRP) or polyethylene terephthalate (PET).
  • CFRP carbon fiber reinforced plastic
  • PET polyethylene terephthalate
  • First projection 4 of first material 1 and second projection 5 of third material 3 are substantially identical in shape in the present exemplary embodiment.
  • the clearance between outer edge region 19 of first projection 4 and second projection 5 opposing each other, and the rim of first through-hole 11 of second material 2 is referred to as first gap 7 .
  • a clearance in the thickness direction between first projection 4 and second projection 5 positioned in first through-hole 11 is referred to as second gap 8 .
  • the region inside the inner edge of projections 4 and 5 when seen from above is referred to as inner edge region 10 of projections 4 and 5 .
  • welding is performed by applying arc 15 , from above first material 1 , to inner edge region 10 of second projection 5 (see FIGS. 1 and 4 ), which is the region that can be joined.
  • first material 1 corresponds to the first metallic material of the present disclosure
  • third material 3 corresponds to the second metallic material of the present disclosure.
  • thickness direction is defined as the direction perpendicular to the main surfaces of first, second, and third materials 1 , 2 , and 3 before welding, and is shown by the arrows in FIG. 1 .
  • second gap 8 in the thickness direction during and after welding will now be described with reference to FIG. 1 .
  • Arc spot welding is performed by applying arc 15 to inner edge region 10 of projections 4 and 5 so as to form weld 16 .
  • the molten metal of weld 16 is solidified and shrunk while first material 1 and third material 3 are being welded. This results in shrinking second gap 8 between projections 4 and 5 .
  • the size of second gap 8 is set at 4% to 75% of the thickness of first material 1 or third material 3 to which arc 15 is applied.
  • the solidification shrinkage of weld 16 functions as compressive force 18 of first material 1 and third material 3 to compress second material 2 , so that second material 2 can be compressed and fixed between first material 1 and third material 3 .
  • the range of 4% to 75% is calculated from experimental data. An example of the data is shown in FIG. 6 .
  • FIG. 6 is a graph showing the measurement results of the relationship between the thickness t of first projection 4 of the first material and the size of second gap 8 between projections 4 and 5 in the thickness direction.
  • first material 1 and third material 3 are both mild steel, and second material 2 is PET.
  • First material 1 is placed on third material 3 , and metal active gas (MAG) arc welding is applied at an output current of 100 A to 250 A for 0.3 seconds.
  • Arc 15 is applied, from above in the thickness direction, to inner edge region 10 of first projection 4 , which is the region to be irradiated.
  • This arc welding is performed under the following conditions: inner edge region 10 of projections 4 and 5 is an area with a diameter of ⁇ 10 mm; and first through-hole 11 of second material 2 has a diameter of ⁇ 12 mm.
  • the region to be irradiated with arc 15 that is applied to projections 4 and 5 in the thickness direction is set smaller, by a predetermined distance, than the diameter or width of projections 4 and 5 .
  • the spot diameter is ⁇ 8 mm, which is similar to and smaller than inner edge region 10 to which arc 15 is applied.
  • second gap 8 can be in the range of 0.1 mm to 0.6 mm in order to allow second material 2 to be compressed and fixed by the solidification shrinkage of the molten metal in weld 16 . If second gap 8 is larger than 0.6 mm, there will be holes in weld 16 , demonstrating a defective weld. Therefore, the effective range of second gap 8 is between 13% and 75%, inclusive of the thickness of first material 1 .
  • second gap 8 can be in the range of 0.1 mm to 1.4 mm in order to allow second material 2 to be compressed and fixed by the solidification shrinkage of the molten metal in weld 16 . If second gap 8 is larger than 1.4 mm, there will be holes in weld 16 , demonstrating a defective weld. Thus, successful welding can be obtained by determining the size of second gap 8 in the thickness direction according to the thickness of first material 1 to which arc 15 is applied. To be more specific, the appropriate size of second gap 8 is from 4% to 61%, inclusive of the thickness of first material 1 .
  • molten metal corresponding to up to 60% to 75% of the thickness t of first material 1 flows into second gap 8 to achieve a joint with no hole in the weld. If exceeding 60% to 75% of the thickness t of first material 1 , second gap 8 cannot be filled with the molten metal, causing the weld to have holes.
  • arc welding performed using welding wire 14 which is a consumable electrode, has a large gap tolerance. This is because the deposition of the molten metal of welding wire 14 in weld 16 increases the proportion of second gap 8 with respect to the thickness t of first material 1 to which arc 15 is applied.
  • second gap 8 between projections 4 and 5 is smaller than 0.1 mm, compressive force 18 , which is generated when first and third materials 1 and 3 are melted and joined together, is too small to compress and fix second material 2 in between.
  • the solidification shrinkage of weld 16 in second gap 8 during welding increases with an increase in the size of second gap 8 within the range of ensuring the necessary amount of molten metal, or in other words, within the range of not generating holes.
  • First projection 4 of first material 1 and second projection 5 of third material 3 are identical in shape in the present exemplary embodiment, but are not necessarily identical. Furthermore, arc 15 is not necessarily applied from the first material 1 side. If the size of second gap 8 is set at 4% to 61%, inclusive, of the thickness of the region to be irradiated of first material 1 or third material 3 to which arc 15 is applied, second gap 8 can be completely filled with molten metal. As a result, the solidification shrinkage of weld 16 allows second material 2 to be compressed and fixed between first material 1 and third material 3 . Therefore, arc welding can be performed by applying arc from below instead of from above, or in other word, from the third material 3 side.
  • first material 1 and third material 3 are similar types of metallic materials, namely, mild steel in the present exemplary embodiment.
  • materials 1 and 3 may be different types of metallic materials from each other as long as they are weldable to each other and have sufficient joint strength.
  • First material 1 and third material 3 can be a combination of ferrous metals, such as two types of mild steel; two types of stainless steel; two types of high-tensile steel; mild steel and high-tensile steel; and high-tensile steel and stainless steel.
  • Materials 1 and 3 can also be a combination of nonferrous metals, such as two types of aluminum; two types of aluminum alloys; and aluminum and an aluminum alloy.
  • second material 2 can be copper, which is difficult to be arc welded; resin; or other materials that are difficult to be welded to first material 1 and third material 3 (e.g., first and third materials 1 and 3 are mild steel, and second material 2 is aluminum, or vice versa).
  • second materials 2 can be sandwiched between first and third materials 1 and 3 as similar types of metallic materials and be joined together by arc welding, with second gap 8 in a proper state.
  • second materials 2 sandwiched between first and third materials 1 and 3 can be compressed and fixed by compressive force 18 generated by the solidification shrinkage of the molten metal of first and third materials 1 and 3 .
  • the region, of first projection 4 , to be welded by arc 15 applied in the thickness direction is smaller than inner edge region 10 and smaller than the diameter or width of first projection 4 by a predetermined distance.
  • a key to successful melting of second material 2 due to the heat transferred from weld 16 by the welding heat input is the positional relationship between outer edge region 19 of projections 4 and 5 to which arc 15 is applied and the rim of first through-hole 11 of second material 2 .
  • first gap 7 between outer edge region 19 of projections 4 , 5 and the rim of first through-hole 11 of second material 2 is in a proper range.
  • part of second material 2 that is around first through-hole 11 is melted by the welding heat input while first and third materials 1 and 3 are being welded.
  • the molten part of second material 2 flows and is tightly fixed around outer edge region 19 of projections 4 and 5 .
  • the welding heat input to first projection 4 indirectly heats and melts the part of second material 2 that is around first through-hole 11 , so that the molten part of second material 2 flows and is tightly fixed to the outer periphery of first projection 4 .
  • second material 2 can not only be compressed and fixed by the solidification shrinkage of weld 16 but also be tightly fixed to outer edge region 19 of projections 4 and/or 5 in the direction crossing the thickness direction of second material 2 .
  • first gap 7 If welding is performed when first gap 7 is very small, the part of second material 2 that is around first through-hole 11 is excessively subjected to the heat from around outside outer edge region 19 of projections 4 and 5 to which the welding heat input to weld 16 is transferred during the application of arc 15 . This may cause the molten part of second material 2 that is around first through-hole 11 to flow into second gap 8 . Moreover, when made of resin or other low-boiling-point materials, second material 2 may vaporize and blow off, causing weld 16 to be defective.
  • first gap 7 between the rim of first through-hole 11 and outer edge region 19 is at least 2.0 mm when second material 2 is resin, or is at least 1.5 mm when second material 2 is CFRP.
  • second material 2 is CFRP.
  • first gap 7 is the distance at which the heat of arc 15 is transferred from outer edge region 19 to first through-hole 11 , and by the type of second material 2 .
  • the positioning of projections 4 and 5 with respect to the diameter of first through-hole 11 into which projections 4 and 5 are positioned can be achieved by using an unillustrated clamping tool, a positioning pin, or a robot arm for supporting and positioning.
  • the size of outer edge region 19 of embossed projections 4 and 5 actually corresponds to the offset in the range of about 1 mm to the thickness of materials 1 and 3 ; however, the size of outer edge region 19 in the present disclosure is simplified as 1 mm.
  • FIG. 7 is a graph showing the measurement results of the relationship between the type of second material 2 and the size of first gap 7 .
  • the types of second material 2 shown in FIG. 7 are the following: PET and CFRP, which are resin materials; and an A5000 series aluminum alloy, which is nonferrous metal.
  • First gap 7 is the clearance between the rim of first through-hole 11 of second material 2 and outer edge region 19 of projections 4 and 5 of first material 1 and third material 3 .
  • first material 1 and third material 3 are mild steel with a thickness tof 1.6 mm.
  • Second material 2 which is one of the different types and has a thickness t of 2.0 mm, is sandwiched between materials 1 and 3 .
  • MAG arc welding is applied to these stacked materials at an output current of 100 A to 250 A for 0.3 seconds.
  • Arc 15 is applied from above to inner edge region 10 of first projection 4 , which is the region to be irradiated.
  • inner edge region 10 of projections 4 and 5 is an area with a diameter of ⁇ 10 mm; first through-hole 11 of second material 2 has a diameter of ⁇ 12 mm; and the spot diameter of ⁇ 8 mm, which is similar to inner edge region 10 .
  • first gap 7 can be at least 0.8 mm, or in other words, at least 40% of the thickness of second material 2 .
  • first gap 7 can be at least 0.8 mm, or in other words, at least 40% of the thickness of second material 2 .
  • first gap 7 is less than 0.8 mm, or in other words, less than 40% of the thickness of second material 2 , and that outer edge region 19 is too close to the rim of first through-hole 11 of second material 2 .
  • second material 2 is partly melted by the heat generated by the welding of inner edge region 10 of projections 4 and 5 .
  • the molten part of second material 2 flows into second gap 8 between projections 4 and 5 and may vaporize and blow off, causing weld 16 to be defective.
  • first gap 7 can be at least 0.6 mm, or in other words, at least 30% of the thickness of second material 2 .
  • first gap 7 is less than 0.6 mm, or in other words, less than 30% of the thickness of second material 2 , and that outer edge region 19 is too close to the rim of first through-hole 11 of second material 2 .
  • second material 2 is partly melted by the heat generated by the welding of inner edge region 10 of projections 4 and 5 .
  • the molten part of second material 2 flows into second gap 8 between projections 4 and 5 and may vaporize and blow off, causing weld 16 to be defective.
  • the properties such as the melting and boiling points of the resin material of second material 2 to be sandwiched between the similar types of metallic materials influence the allowable size of first gap 7 during welding. Compared with laser welding, arc welding has a high heat input due to arc heat, so that first gap 7 has a narrow tolerance.
  • second material 2 is an A5000 series aluminum alloy, which is an example of nonferrous metal.
  • the molten part of second material 2 is prevented from flowing into second gap 8 between projections 4 and 5 and from causing weld 16 to be defective.
  • second material 2 can be compressed and fixed in a stable manner.
  • second material 2 is a resin material
  • fiber reinforced resins have tendencies similar to those of CFRP.
  • second material 2 is an A5000 series aluminum alloy, which is nonferrous metal.
  • A5000 series aluminum alloy which is nonferrous metal.
  • weld 16 to be defective due to the welding heat input generated by the application of arc 15 to projections 4 and 5 .
  • Other nonferrous metals have similar tendencies.
  • the second material is nonferrous metal, it never occurs that part of second material 2 is melted by heat, and that the molten part flows into second gap 8 between projections 4 and 5 .
  • FIG. 5 shows an example of the projection with a shape other than a circle.
  • first material 1 as the upper plate in the thickness direction is rectangular-shaped so that the welding seam is straight.
  • the longitudinal side of a rectangular joint structure is arranged in the direction in which a high joint strength is needed. This requires a smaller area than in the case that first projection 4 and second projection 5 are large square-shaped.
  • the straight welding seam shown in FIG. 5 takes less time than joining a plurality of positions of a circular projection.
  • FIGS. 8 and 9 show examples of increasing the joining strength and simplifying the positioning.
  • first material 1 functions to position second material 2 .
  • second material 2 is brought into contact with the stepped portion of first material 1 and is sandwiched between first material 1 and third material 3 .
  • the joint structure shown in FIG. 8 has an improved tensile strength of the joint.
  • the joint structure is a double-supported structure in which first material 1 having first projection 4 is joined with third material 3 at weld 16 via second material 2 , and is further joined directly to third material 3 at weld 16 a .
  • first material 1 having first projection 4 is joined with third material 3 at weld 16 via second material 2
  • third material 3 is further joined directly to third material 3 at weld 16 a .
  • an external force such as the tensile or torsion stress of second material 2
  • third material 3 which prevents stress concentration on weld 16 between first material 1 and third material 3 , which are joined via second material 2 .
  • This improves the joining strength between the similar types of metallic materials and the different type of material, and hence, the joining strength of the entire joint structure.
  • Third material 3 can be folded as shown in FIG. 9 , so that the upper plate part of third material 3 can substitute for first projection 4 of first material 1 so as to sandwich second material 2 without using first material 1 .
  • This configuration eliminates the need to use a jig for fixing first material 1 .
  • This configuration also makes it possible to insert second material 2 into third material 3 for temporary fixation, thereby facilitating the positioning of second material 2 .
  • first metallic material of the present disclosure corresponds to the upper plate part formed by folding third material 3 .
  • the second metallic material of the present disclosure corresponds to the lower plate part formed by folding third material 3 .
  • first and second metallic materials of the present disclosure may be integrated before welding.
  • the joint structure of the present exemplary embodiment welded with arc 15 includes a first metallic material having first projection 4 ; a second metallic material similar in type to the first metallic material and weldable to the first metallic material; and a different type of material different in type from the first metallic material and the second metallic material, the different type of material having first through-hole 11 and sandwiched between the first metallic material and the second metallic material, the different type of material being difficult to be welded to the first metallic material and the second metallic material.
  • First projection 4 is smaller in diameter or width than first through-hole 11 and is spaced radially or widthwise from the rim of first through-hole 11 by first gap 7 .
  • First projection 4 is positioned in first through-hole 11 and is spaced from the second metallic material by a second gap 8 in the thickness direction of first through-hole 11 .
  • Second gap 8 has a size of the predetermined percentage of the thickness of first projection 4 of the first metallic material to which arc in arc welding is applied.
  • the first metallic material and the second metallic material are melted and joined together inside first through-hole 11 to compress and fix the different type of material, so that the different type of material, the first metallic material, and the second metallic material are fixed together.
  • the welding described in the present exemplary embodiment is arc welding with a consumable electrode; however, it is alternatively possible to employ TIG or plasma welding (not shown) with a non-consumable electrode.
  • a second exemplary embodiment will now be described with reference to FIG. 2 .
  • the same configuration as in the first exemplary embodiment will not be described again.
  • the second exemplary embodiment differs from the first exemplary embodiment in that first material 1 has first projection 4 but third material 3 does not have second projection 5 .
  • the absence of second projection 5 in third material 3 can reduce the processing cost of materials.
  • Another advantage is that the positioning of first material 1 and second material 2 is not affected by the misalignment of third material 3 .
  • arc welding is performed when first through-hole 11 has a second gap 8 between the first and third materials in the thickness direction. This allows the solidification shrinkage of weld 16 to function as compressive force 18 for compressing and fixing second material 2 sandwiched between first material 1 and third material 3 .
  • First projection 4 is formed on first material 1 in the present exemplary embodiment, but may alternatively be formed on third material 3 .
  • the first metallic material of the present disclosure corresponds to third material 3
  • the second metallic material of the present disclosure corresponds to first material 1 .
  • the size of second gap 8 is small enough not to cause burn-through of first or third material 1 or 3 due to arc 15 with respect to the thickness of first or third material 1 or 3 to which arc 15 is applied. This enables arc welding to be applied either from the first material 1 side or from the third material 3 side.
  • first projection 4 is formed on the surface of the first metallic material that opposes the second metallic material so as to sandwich the second material (the different type) inside first through-hole 11 (the first penetrating part).
  • first projection is formed on the surface of at least one of the opposing surfaces of first and third materials 1 and 3 . Therefore, second material 2 and at least of one of first and third materials 1 and 3 that has the first projection are not affected by the misalignment of the other of first and third materials 1 and 3 that does not have the first projection.
  • neither of the first and third materials 1 and 3 as the similar types of metallic materials may have a projection.
  • arc welding is performed in a similar manner to the first exemplary embodiment.
  • Arc 15 is applied to the region to be irradiated in first through-hole 11 with second gap 8 corresponding to the thickness of second material 2 sandwiched between first and third materials 1 and 3 .
  • the solidification shrinkage of weld 16 functions as compressive force 18 for compressing and fixing second material 2 .
  • the thickness of second material 2 which is equal to the size of second gap 8 , is a predetermined percentage of the thickness t of first metallic material 1 to which arc 15 is applied (see FIG. 6 ).
  • a third exemplary embodiment will now be described with reference to FIGS. 10 to 12 .
  • the same configuration as in the first and second exemplary embodiments will not be described again.
  • the third exemplary embodiment differs from the first exemplary embodiment in that first projection 4 of first material 1 to which arc 15 is applied has second through-hole 6 at its center.
  • Second through-hole 6 (which is an example of the second penetrating part of the present disclosure) is smaller than the weld region to which arc 15 is applied.
  • first projection 4 is shaped like a flange.
  • Second through-hole 6 makes it unnecessary to make an opening in first material 1 as the upper plate with arc heat in order to melt and join first material 1 with third material 3 .
  • Second through-hole 6 also allows the molten metal of the welding wire to stimulate the melting of first material 1 and third material 3 , thereby firmly joining the opposing surfaces of projections 4 and 5 .
  • first material 1 as the upper plate has a small thickness t (e.g., less than 1.0 mm).
  • This design is inappropriate when the thickness t is large (e.g., larger than 1.0 mm) because it requires a quantity of heat large enough to burn-through first material 1 as the upper plate.
  • having second through-hole 6 at the center of first projection 4 of first material 1 as in the third exemplary embodiment is very effective as long as first material 1 as the upper plate has a large thickness t (e.g., 1.0 mm or more).
  • third material 3 does not necessarily have second projection 5 as shown in FIG. 11 , unlike the first exemplary embodiment.
  • neither of first and third materials 1 and 3 may have a projection as shown in FIG. 12 .
  • a fourth exemplary embodiment will now be described with reference to FIG. 13 .
  • the same configuration as in the first exemplary embodiment will not be described again.
  • the fourth exemplary embodiment differs from the first exemplary embodiment in that a plurality of discharge holes 17 or discharge grooves are formed, which penetrate either first material 1 or third material 3 in the thickness direction.
  • Discharge holes 17 or discharge grooves are provided outside the region where projections 4 and 5 are in contact with each other in the direction perpendicular to the thickness direction.
  • discharge holes 17 or discharge grooves are provided outside first through-hole 11 in the direction perpendicular to the thickness direction.
  • Discharge holes 17 and discharge grooves are examples of the discharge opening of the present disclosure.
  • discharge holes 17 can be formed in at least one of the similar types of metallic materials which sandwich and fix the different type of material in between. In this case, discharge holes 17 can prevent the molten part of second material 2 from flowing into weld 16 while arc 15 is being applied to it, and accelerates the discharge of the molten part to the outside.
  • Discharge holes 17 are provided in third material 3 in the present exemplary embodiment, but may alternatively be provided in first material 1 or in both first and third materials 1 and 3 . Still alternatively, the discharge holes may be replaced by, for example, long discharge grooves.
  • Conventional rivets for joining different types of materials together have complicated shapes such as an R-chamfered part or an annular groove for the following objectives; to create a space to accommodate the part of the different type of material that is deformed during crimping and spot welding; and to prevent misalignment of the electrode during spot welding, and hence, to prevent depression of the different type of material so as to maintain the joint strength.
  • rivets with a complicated shape.
  • Such rivets can be fabricated by high precision processing technology, thus increasing the production cost.
  • spot welding has low throughput because it involves time-consuming processes, such as pressurization, energization, cooling, and transfer.
  • the joint members are sandwiched from both sides, which indicates a low degree of design freedom. Adjacent rivets too close to each other can cause current diversion during spot welding. This would result in insufficient formation of a nugget, which is a part welded and solidified in the resistance welding.
  • a desired nugget without current diversion can be formed by setting the pitch between adjacent rivets at not less than the minimum pitch. Therefore, rivets cannot be arranged at a pitch not more than the minimum pitch, making it impossible to improve joint stiffness at required positions.
  • the present disclosure can solve these conventional problems.
  • the joint structure of some exemplary embodiment includes, a first metallic material having first projection 4 ; a second metallic material similar in type to the first metallic material and weldable to the first metallic material; and a different type of material different in type from the first metallic material and the second metallic material, the different type of material having first through-hole 11 and sandwiched between the first metallic material and the second metallic material, the different type of material being difficult to be welded to the first metallic material and the second metallic material.
  • First projection 4 is smaller in diameter or width than first through-hole 11 and is spaced radially or widthwise from the rim of first through-hole 11 by first gap 7 .
  • First projection 4 is positioned in first through-hole 11 and is spaced from the second metallic material by a second gap 8 in the thickness direction of first through-hole 11 .
  • Second gap 8 has a size of the predetermined percentage of the thickness of first projection 4 of the first metallic material to which arc in arc welding is applied.
  • This joint structure eliminates the need to use complicated parts that are fabricated by high precision processing technology.
  • the use of arc welding instead of spot welding reduces the operating time including welding time to about 25% of spot welding, thereby greatly improving the throughput.
  • Another advantage is to increase the stiffness at required positions and the degree of design freedom of joint members.
  • First projection 4 may be formed on the surface of the first metallic material that opposes the second metallic material when the first metallic material and the second metallic material sandwich the different type of material via first through-hole 11 .
  • the second metallic material may have second projection 5 .
  • Second projection 5 is formed on the surface of the second metallic material that opposes the first metallic material when the first metallic material and the second metallic material sandwich the different type of material via first through-hole 11 of the different type of material.
  • Part of the different type of material that is around first through-hole 11 may melt, flow, and be tightly fixed to the outer periphery of first projection 4 .
  • the weld region to be arc welded in the thickness direction may be smaller in diameter or width than first projection 4 by a predetermined distance.
  • First projection 4 may have second through-hole 6 so as to have the shape of a flange with a central hole, second through-hole 6 being in the weld region to be arc welded in the thickness direction.
  • At least one of the first metallic material and the second metallic material sandwiching the different type of material in between may have discharge holes 17 penetrating in the thickness direction, discharge holes 17 being located in a position corresponding to the outside of first through-hole 11 of the different type of material.
  • the arc welding may be one of the following types of welding: arc welding with a consumable electrode, TIG welding with a non-consumable electrode, and plasma welding with a non-consumable electrode.
  • the joint structure of the present disclosure is simple and can greatly reduce the production cycle time and increase stiffness at required positions when different types of materials are joined together.
  • This joint structure which can increase the degree of design freedom of joint members, is industrially applicable.

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  • Butt Welding And Welding Of Specific Article (AREA)
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